Non-cryogenic nitrogen for on-site downhole drilling and post drilling operations

ABSTRACT

A method for enhancing gas or oil production by delivering a nitrogen rich gas produced from a non-cryogenic source into the well and/or reservoir where the gas and/or oil is located.

RELATED APPLICATIONS

This is a Continuation Application of U.S. Ser. No. 09/391,735 filedSep. 8, 1999 now U.S. Pat No. 6,206,113 which is a ContinuationApplication of U.S. Ser. No. 09/173,285 filed Oct. 15, 1998 which issuedas U.S. Pat. No. 6,041,873 on Mar. 28, 2000 which is a ContinuationApplication of U.S. Ser. No. 08/944,919 filed on Oct. 6, 1997 whichissued as U.S. Pat. No. 5,862,869 on Jan. 26, 1999 which is aContinuation Application of U.S. Ser. No. 08/707,352 filed on Sep. 4,1996 which issued as U.S. Pat. No. 5,749,422 on May 12, 1998 which is aContinuation-In-Part Application of U.S. Ser. No. 08/077,014 filed onJun. 14, 1993 which issued as U.S. Pat. No. 5,388,650 on Feb. 14,1995.

FIELD OF THE INVENTION

The present invention is directed to methods of drilling for oil, gas orgeothermal wells and the like as well as post-drilling operations whichemploy an inert gas in the downhole region or in the reservoir. Theinert gas, typically a nitrogen rich gas, is supplied on-site by thepreferential separation of air using a non-cryogenic source of the inertgas such as a membrane or a pressure swing adsorption system.

BACKGROUND OF THE INVENTION

U.S. patent application Ser. No. 08/077,014 filed on Jun. 14, 1993,incorporated herein by reference discloses a method for injecting anon-cryogenic inert gas such as nitrogen gas in the downhole regionduring drilling operations, to remove drill cuttings. This methodpresents advantages over downhole drilling using combustible gases suchas air and cryogenic fluids such as liquid nitrogen.

Drilling and post-drilling operations efficiently establish a well,cement or secure casings or other tubular members within the well andremove the desirable payloads (e.g. gas and/or oil) from the well ordirectly from the reservoir containing the same. Methods of performingthese operations are well-known.

Generally, the drilled wells are provided with tubular casings whichsecure the perimeter of the wellbore. Sometimes multiple casings(intermediates) are secured from the surface of the well to lowerdownhole locations. Other types of casings, called liners, are sometimesused to extend from the lowermost casing into the lowermost portion ofthe wellbore. Drilling fluids, such as drilling mud, are often used whenlarge flows of water are present in the well. The drilling mud iscirculated down the drill string, through the drill bit, and up theannular region between the drill string and the wellbore or casing tothe surface. Gas may be injected in the downhole region to providefaster drilling rates when substantial amounts of water are not presentin the well.

Air has been used as the principal downhole drilling fluid for low watercontent drilling. The air can be combined with a surfactant, foamingagent, water and/or mud for different applications. The primaryadvantages of straight air drilling are greatly increased penetrationrates, greater bit footage and fewer downhole drilling problems.

Downhole drilling with air, however, does have a number ofdisadvantages, one of the most important of which is the occurrence ofdownhole explosions or fire due to the presence of high levels of oxygenin air. Efforts have been made to reduce the hazards of air drilling bylowering the temperature of the air or by replacing air with an inertgas. U.S. Ser. No. 08/077,014 discusses prior art efforts to solve theproblem and discloses the advantages of using non-cryogenic inert gases(e.g. nitrogen) for this purpose.

There are other significant problems encountered in drilling andpost-drilling operations. When a drilling fluid (e.g. drilling mudincluding optional chemicals and additives) is introduced into thedownhole region, the weight of the drilling fluid creates a hydrostaticpressure proportional to the density of the fluid. The deeper the well,the greater the hydrostatic head pressure developed by the column of thedrilling fluid.

The weight of the drilling fluid can be adjusted at the surface bychanging the mud weight, or changing to a more or less dense drillingfluid. The drilling fluid can be lightened by comingling the drillingfluid with a lower density fluid such as a gas. Nitrogen gas isadvantageous for this purpose because it is inert and non-corrosive.

In drilling operations, the formation pressure of the reservoir (i.e.the pressure exerted by the gas and/or oil) will vary throughout thedownhole region. When the formation pressure is equal to the hydrostaticpressure of the drilling fluid, the fluid system is said to be balanced.If the formation pressure is less than the hydrostatic pressure of thedrilling fluid, the system is overbalanced. Greater formation pressurethan hydrostatic pressure results in an underbalanced system.

By maintaining an underbalanced system (i.e. the formation pressureexceeds the hydrostatic pressure of the drilling fluid), the formationpressure causes a net flow of the gas and/or oil into the wellbore. Thedensity of the drilling mud must often be reduced to generate anunderbalanced drilling condition. Air has been used to reduce thedensity of the drilling mud. However, under some circumstances, thepresence of combustible air in the downhole region can create explosiveconditions.

Another problem associated with downhole drilling relates to theinstallation of the casings and liners. Quite often the casings rubagainst the sides of the wellbore which makes installation difficult andcan cause damage to the casing and/or the wellbore or formation ofinterest. The drill string, as well as subsequent casings or liners, areoften filled with a drilling fluid and can become stuck in the downholeregion, particularly when at least a portion of the downhole region ofthe well extends horizontally. In addition, the cementing of the casingswithin the downhole region is difficult because the cement has limitedflexibility with regard to flow properties and weight distribution.

Post drilling operations also suffer from a number of difficulties. Theremoval of gas and/or oil from the downhole region presents severalproblems to drillers. First, gas and/or oil removal is inhibited by thepresence of water and debris in the well. Second, the withdrawal of thegas and/or oil from deep wells requires high pressure equipment todisplace the heavy well fluids from the well. Third, the permeability ofthe downhole region of the well often decreases over time therebydecreasing the rate at which gas and/or oil enter the production stringfrom the reservoir. Fourth, gas and/or oil production depend on thepressure on the fluids within the reservoir. As the pressure decreases(depletes), production will decrease. Quite often production will ceasefrom the lack of formation pressure even when significant amounts of gasand/or oil remain in the reservoir.

It would be a significant advance in the art of drilling for gas, oiland geothermal wells if the drilling and post drilling operations couldbe improved and particularly if an inert gas, typically a nitrogen richgas, could be conveniently and efficiently supplied to the downholeregion of the well and/or reservoir to eliminate or at least reduce theaforementioned problems.

SUMMARY OF THE INVENTION

The present invention is generally directed to a method of drilling forgas and/or oil or a geothermal well and the like in which a compressedinert gas is delivered to a target such as a well, and/or a reservoircontaining oil and/or gas. The inert gas is obtained from an on-sitenon-cryogenic source. In particular, the source of the inert gas is airwhich is preferentially separated into an inert gas rich fraction and anoxygen waste gas fraction such as by membrane separation or by pressureswing adsorption or the like.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings in which like reference characters indicate likeparts are illustrative of embodiments of the invention and are notintended to limit the invention as encompassed by the claims formingpart of the application.

FIG. 1 is a schematic view of an embodiment of the invention showing anabove surface apparatus for generating a nitrogen rich gas from anair-separation membrane to be delivered to the well and/or reservoir;

FIG. 2 is a schematic view similar to FIG. 1 in which a nitrogen richgas is generated by a pressure swing adsorption unit;

FIG. 3 is a schematic view of a two bed pressure swing adsorption systemfor generating a nitrogen rich gas;

FIG. 4 is a schematic view of a surface equipment installation fordelivering the inert gas to the well and/or reservoir;

FIG. 5 is a schematic view of a drill stem arrangement showing thedelivery of the inert gas to the downhole drilling region;

FIG. 6 is a cross-sectional schematic view of a well with a horizontallydisposed section including appropriate casings and upper and lowerliners with a nitrogen rich gas present therein;

FIG. 7A is a cross-sectional schematic view showing the initialinjection of a cement slurry for cementing a casing within the well;

FIG. 7B is a cross-sectional schematic view of the casing shown in FIG.7A with the cement in place to secure the casing within the well;

FIG. 8 is a cross-sectional schematic view of a well and equipment forremoving gas and/or oil from the well with the assistance of a nitrogenrich gas; and

FIG. 9 is a cross-sectional schematic view of a reservoir and theinjection of a nitrogen rich gas to remove gas and/or oil from thereservoir.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to the on-site non-cryogenicproduction of an inert gas, typically a nitrogen rich gas and itsdelivery to a well and/or reservoir for the drilling of gas and/or oilor geothermal wells and the like. As used herein the term “nitrogen richgas” shall refer to a gas containing predominantly nitrogen gas and nomore than 10% oxygen gas by volume. The nitrogen rich gas is producedfrom air by a number of different methods including membrane separation,pressure swing adsorption, vacuum swing adsorption, fuel cells and thelike.

Referring to FIG. 1 there is shown an above ground installation forproducing a nitrogen rich gas using membrane separation and for deliveryof the nitrogen rich gas to the well and/or reservoir. A feed aircompressor 2 includes an intake port 4 for receiving ambient air and acompressor 6 for pressurizing the air to a suitable pressure, typicallyin the range from about 100 to 350 psig.

The compressed air is sent through a conduit 8 to an air separationmembrane system shown generally by numeral 10, such as a highperformance air separation membrane system manufactured by GeneronSystems, Inc. of Houston, Texas.

The membrane is composed of bundles of hollow fiber, semipermeablemembranes which are assembled parallel to a central core tube. Thebundle is placed into an outer case to form an air separation module.The air is divided into two streams; a nitrogen rich stream and a streamrich in oxygen and water vapor.

When the compressed air is introduced to the feed side of the membranefibers, the air travels down the bore of the hollow permeable fibers.Oxygen, water vapor and other “fast gases” pass through to the outsideof the fibers. The oxygen-rich gas stream then flows through the fiberbundle to the periphery of the outer case of the separator system whereit is discharged as a by-product.

While all but a small fraction of the oxygen passes through the membranematerial to the exterior of the hollow fibers, most of the nitrogenpresent in the feed air is contained within the hollow fiber membrane.As a result, the nitrogen rich gas is effectively separated from thefeed air and exits the membrane system 10 via a conduit 12 for entryinto an optional booster compressor 14.

The booster compressor 14 is employed to elevate the pressure of thenitrogen rich gas. The pressure of the gas obtained from the airseparation membrane system 10 is from about 100 to 200 psig. The boostercompressor 14 is capable of raising the pressure of the nitrogen richgas from as low as 200 psig up to or exceeding 4500 psig and even ashigh as about 10,000 psig, but typically in the range of from about1,000 to 2,000 psig. The highly compressed nitrogen rich gas leaves thebooster compressor 14 via a conduit 16 and is sent to a surfaceequipment installation 18 of the drilling operation as explained indetail hereinafter.

The nitrogen rich gas may also be produced by a pressure swingadsorption system in accordance with the present invention. Referring toFIGS. 2 and 3, there is disclosed a pressure swing adsorption unit 20having two beds “A” and “B”. It should be understood, however, that thepresent invention is applicable to pressure swing adsorption unitshaving an alternate construction such as a greater number of beds.

Referring to FIG. 3, air from a source (not shown) is fed to acompressor 6 to raise the pressure of the air, to accumulate compressedair during the non-production phase and to output compressed air duringpeak loading of the beds. The compressed air is fed to a storage vessel22. The compressed air is then fed via the conduit 24, 26 to an outlet28 leading to bed A and an outlet 30, leading to bed B. Each outlet 28,30 is controlled by respective valves 32, 34. When valve 32 is opened,allowing the compressed air to reach bed A, valve 34 remains closed sothat bed B may undergo regeneration during the depressurization phase ofthe pressure swing adsorption unit 20.

The compressed air enters the bed A through the open valve 32 via aconduit 36. The bed A contains at least one adsorption material capableof preferentially adsorbing oxygen and other waste gases. The preferredadsorbents are selected from molecular sieves and silica gel. As aresult, substantially pure nitrogen passes out of the bed A through aconduit 38, a valve 40 and into a nitrogen storage vessel 42 via aproduct line 44 for passage via a conduit 82 to the optional boostercompressor 14 shown in FIGS. 1 and 2.

While bed A is producing nitrogen gas, bed B is at atmospheric pressure.Upon completion of the nitrogen production cycle in bed A, the systemundergoes equalization to raise the pressure in bed B to an intermediatepressure. This is accomplished by closing the nitrogen product valves40, 46 and the compressed air intake valves 32, 34. Thus, the input ofcompressed air and the output of nitrogen product are temporarilysuspended.

Equalization is accomplished by passing a portion of the pressurized gasfrom the top of the bed A via a conduit 38, valve 50, a conduit 52,restrictive orifice 54, through a conduit 56 and into the top of the bedB. In addition, pressurized gas is passed from the bottom of the bed Avia the conduit 36, a valve 58, a conduit 60, a restrictive orifice 62and a conduit 64 into the bottom of bed B.

Once equalization is completed so that bed A and B are at similarpressures, bed A undergoes regeneration by depressurizing to atmosphericpressure to remove the oxygen enriched waste gases. This is accomplishedby closing the equalization valves 50, 58 and opening a regenerationvalve 66 for the bed A. The waste gas is then vented to the atmospherethrough a conduit 68 and a restrictive orifice 70. As a consequence, thebed A is regenerated.

Further cleansing of the bed A may be made by passing a purge gas, suchas substantially pure nitrogen gas, from a source 72, through conduits74 and 76, respectively, a valve 78 and into bed A via the line 38. Whenthe bed B is further cleansed, the purge gas passes through the conduits74 and 76, respectively, a valve 80 and the conduit 56. After purging,the adsorbents are ready for adsorbing waste gases in a new nitrogenproduction cycle.

Since the pressure in bed B has been raised to an intermediate pressure,it is ready to receive compressed air. The compressed air is providedthrough the valve 34 and the conduit 64. It may be necessary, in orderto get sufficient compressed air to quickly load bed B up to operatingpressure, for the compressed air feed generated by the compressor 6 tobe supplemented by compressed air already stored in the storage vessel22.

Once bed B has been loaded, the valve 46 is opened, allowing product gasto enter the product line 44 via the conduit 56 from which it enters thestorage vessel 42. A distribution conduit 82 extends from the storagevessel 42 to provide a flow of nitrogen rich product gas to the boostercompressor 14 shown in FIGS. 1 and 2.

After nitrogen production in bed B is completed, the valve 46 is closedas is the valve 34 to stop the compressed air feed. The equalizationcircuit is activated by opening valves 50, 58 and the pressurized gas isfed from the top and bottom of bed B to bed A to raise the pressuretherein to an intermediate pressure level. Bed B is then depressurizedby eliminating the oxygen rich waste gases which are sent via theconduits 64, 84 through a valve 86 to the atmosphere via the conduit 68and restrictive orifice 70.

Thereafter, compressed air from the compressor 6 and the storage vessel22 is fed to bed A through the valve 32 via the conduit 36 to raise bedA to the desired operating pressure thereby commencing the nitrogenproduction cycle from bed A which passes into the booster compressor 14.

The nitrogen rich gas, after compression up to as high as 10,000 psig inthe booster compressor 14, is sent to surface equipment installationshown in FIG. 4.

Referring to FIG. 4, the high pressure nitrogen rich gas obtained fromthe booster compressor 14 is sent to the surface equipment 18 via aconduit 90 through a main block valve 92. The flow rate of the nitrogenrich gas is typically measured by an orifice meter 94. The meterednitrogen rich gas is sent through an adjustable choke 96 and a pressureshut off valve 98 before entering a standpipe 100. In accordance withthe present invention and as explained hereinafter, the nitrogen richgas can be added to the drilling fluid (e.g. drilling mud) to lower thedensity thereof in the standpipe 100 through a conduit 102.

For drilling purposes, the nitrogen rich gas is fed through a Kelly cockor swivel 104, through a Kelly string 106 and into a Kelly packer 108.The Kelly string is a square or hexagonally shaped pipe which canreadily be rotated if necessary in the rotating Kelly packer 108. Thiscauses the entire drill stem assembly 124 and the drill bit 138 (seeFIG. 5) to rotate during drilling operations. If the well to be drilledis deviated or horizontal, an air motor (not shown) is used to providerotary motion in the drilling bit rather than rotating the entire drillstring as is customary in the art.

The nitrogen rich gas continues to flow until it reaches a drill stemassembly 124 (see FIG. 5) which is typically connected in lengths calledpipe stands. The drill stem assembly 124 is fed through the well headassembly (shown generally by numeral 110) which may contain a series ofpipe rams, vents and choke lines. As will be explained hereinafter,there is provided an outlet 112 which is connected to a blooey line fordischarging the exhaust nitrogen gas and drill cuttings.

For non-drilling applications, the drill stem assembly may be removedand the nitrogen rich gas can be pumped into the downhole region throughthe pathway 128.

The surface installation may optionally include an injector manifold 114for injecting chemicals, such as surfactants and special foaming agents,into the nitrogen rich gas feed stream to help dissolve mud rings formedduring drilling or to provide a low density, low velocity circulationmedium of stiff and stable foam chemicals to cause minimum disturbanceto unstable or unconsolidated formations.

Extending below the surface of the ground into the downhole region is adrill stem arrangement which provides a pathway for the flow ofpressurized nitrogen rich gas to the drilling region. There is alsoprovided a second pathway for the flow of nitrogen gas and the drillcuttings out of the downhole region and away from the drillingoperation.

Referring to FIG. 5, the drill stem arrangement shown generally bynumeral 120 includes a surface pipe 122 and casing 123 and the drillstem assembly 124 running concentrically with and spaced apart from thesurface pipe 122 and production casing 123 to define a pathway 126 forthe return nitrogen rich gas and the drill cuttings. The center of thedrill stem assembly 124 provides a pathway 128 for the flow of nitrogenrich gas to the drilling region. At the end 130 of the drill stemarrangement 120, in vicinity of the drilling region 132, is aconventional tool joint 134, a drill collar 136 and a drill bit 138.

The nitrogen rich gas produced by the air separation membrane system 10or the pressure swing adsorption system 20 or other non-cryogenic systemtypically has a nitrogen content of at least about 85% by volume,preferably at least about 95% by volume, and an oxygen content of nomore than 10% by volume, preferably less than about 5% by volume. Thenitrogen rich gas is sent to a booster compressor 14 where the pressureis raised from as low as 200 psig to as high as 10,000 psig or more,typically in the range of about 1,000 to 2,000 psig. The pressurizednitrogen rich gas is sent to the surface installation equipment 18 whereit is monitored and metered into the downhole through the pathway 128within the drill stem assembly 124.

Because the nitrogen rich gas is under pressure, it swirls around thedrilling region 132 with sufficient force and velocity to carry thedrill cuttings upwards into the pathway 126. The drill cuttingcontaining stream then exits the outlet 112 of the surface installationequipment 18 where it is carried to a blooey line and eventuallydiscarded into a collection facility, typically at a location remotefrom the actual drilling site.

The nitrogen rich gas described above for removing drilling cuttings canalso be injected into the drilling fluid to reduce the density thereof.This provides greater control over the drilling fluid and isparticularly adapted for underbalanced drilling where the pressure ofthe drilling fluid is reduced to a level below the formation pressureexerted by the oil and/or gas formation. The nitrogen rich gas can beprovided to the drilling fluid in the following manner.

Referring to FIG. 5, the nitrogen rich gas can be injected into adrilling fluid through an assembly shown in FIG. 5 absent the drill stemassembly 124. In this embodiment of the invention, the nitrogen rich gasis pumped through the pathway 128 which may be in the form of linearpipe strings or continuous coiled tubing known as a drill string.Alternatively, the nitrogen rich gas may be pumped into the annularspace 126 between the drill string or pathway 128 and the casing 123inserted into the well. In this embodiment a drill string may beinserted directly into the annular space 123 to provide the nitrogenrich gas directly therein.

The nitrogen rich gas produced in accordance with the present inventioncan be used to modify the flow properties and weight distribution of thecement used to secure the casings within the well.

Referring to FIGS. 6, 7A and 7B and first to FIG. 6, there is shown thewell 200 supported by tubular casings including an intermediate casing202, a surface casing 204, and a conductor casing 206.

The conductor casing 206 is set at the surface to isolate soft topsoilfrom the drill bit since drilling mud will erode the top section of thewellbore.

The surface casing 204 also extends from the surface of the well and isrun deep enough to prevent any freshwater resources from entering thewellbore. In addition to protecting the fresh water, the surface casing204 prevents the wellbore from caving in and is an initial attachmentfor the blow-out-prevention (BOP) equipment. Typical lengths of thesurface casing 204 are in the range of from about 200 to 2500 ft.

The intermediate casing 202 protects the hole from formations which mayprove troublesome before the target formation is encountered. It is asnamed because it is intermediate in length; longer than the surfacecasing, but shorter than the final string of casing (production casing)123 as shown in FIG. 4.

The production casing (oil string or long string) extends from thebottom of the hole back to the surface. It isolates the prospectiveformation from all other formations and provides a permanent conduitthrough which reserves can be recovered.

The diameter of the various casings decreases as the depth of the casinginto the well 200 increases. Accordingly, the intermediate casing 202extends the furthest into the well 200. The intermediate casing istypically filled with a drilling fluid 208 such as drilling mud.

The process of securing the casing within the well using a cement-likematerial is shown with reference to FIGS. 7A and 7B. Referring first toFIG. 7A, there is shown a well 200 containing a casing 210 which isinitially filled with a drilling fluid 208 such as drilling mud or adrilling mud modified with a nitrogen rich gas in accordance with thepresent invention. A wiper plug 212 is inserted into the casing 210 andurged downward to force the drilling fluid out of the bottom opening 214and up along the annular space 216 between the walls 218 defining thewellbore and the casing 210. The drilling fluid proceeds upwardlythrough the annular space 216 and out of the opening 220 at the top ofthe well 200.

While the drilling fluid is being evacuated a cement-like material inthe form of a slurry is loaded into the casing 210. A second wiper plug222 is then urged downwardly as shown in FIG. 7B to force the cement outof the bottom opening 214 until the annular space 216 is filled. Excesscement escapes out of the opening 220 of the well.

In accordance with the present invention, a nitrogen rich gas producedas described above may be used to reduce the density of the cement in amanner similar to that described for the drilling fluid. The nitrogenrich gas may be injected into the casing while the cement is being addedtherein. The injection of the nitrogen rich gas into the cement modifiesthe density and flow characteristics of the cement while the cement isbeing positioned in the well.

The nitrogen rich gas is injected into the casing through a drill stringof the type described in connection with FIG. 5 with the drill stemassembly 124 removed. The rate of injection and the precise compositionof the nitrogen rich gas is controlled above the surface by the feedrate of air to the membrane separation unit or pressure swing absorptionunit shown in FIGS. 1-3.

The nitrogen rich gas can be used to improve the buoyancy of the casingsso as to minimize the effects of friction as the casings are insertedinto the well. This is particularly apparent when casings are insertedinto horizontal sections in the downhole region. In horizontal sections,the weight of the casing causes it to drag along the bottom surface ofthe wellbore. In extreme cases the casing may become wedged in thewellbore and not be able to be advanced as far into the downhole regionas desirable. Introducing a nitrogen rich gas in accordance with thepresent invention into the interior of the casing will increase thebuoyancy of the casing, allowing it to float in the mud or drillingfluid surrounding the casing.

Referring again to FIG. 6, there is shown a casing assembly including atubular member or liner 224 which is designed to enter a horizontalsection 226 of the well 200. A liner is any length of casing that doesnot extend to the surface of the well.

The liner 224 includes an upper section 228 which contains a drillingfluid and a lower section 230. The upper and lower sections areseparated by an inflatable packer 232. The lower section 230 is chargedwith the nitrogen rich gas which makes it lighter and more buoyant thanthe upper section 228 which is filled with mud. The lower section 230may therefore move more readily into the horizontal section 226 of thewell 200.

After the completion of drilling in the downhole region, nitrogen richgas can be used to improve well performance and maximize output of gasand/or oil from the reservoir. Quite often well production declinesbecause of the presence of fluids, such as water, excess drilling mudand the like in the downhole region. The nitrogen rich gas produced inaccordance with the present invention can be used to clean out the wellby displacing the heavier fluids that collect therein. Removal of theheavier fluids will regenerate the flow of gas and/or oil from thereservoir if there is sufficient formation pressure within thereservoir. The nitrogen rich gas can be used to provide an additionalboost for lifting the gas and/or oil from the downhole region to acollection area. In this case the nitrogen rich gas is pumped down intothe downhole region within the casing under sufficient pressure so thatthe gas and/or oil entering the downhole region from the reservoir islifted upwardly and out of the well.

Referring to FIG. 8, there is shown an assembly particularly suited forinjecting a nitrogen rich gas into the gas and/or oil within thedownhole region to facilitate delivery thereof upwardly through the wellfor collection. Such a system is applicable to downholes having reducedformation pressure. As a result the gas and/or oil has difficultyentering the downhole from the reservoir.

In accordance with the present invention, the nitrogen rich gas isinjected into the annulus 240 between the casing 242 and a tubing 244.The nitrogen rich gas is metered into the tubing 244 through a valveassembly 246. The tubing 244 has an opening 248 enabling gas and/or oilfrom the downhole region to enter and rise up to the surface of thewell. The injection of the nitrogen rich gas from the valve assembly 246into the tubing 244 assists the gas and/or oil by providing buoyancy tothe flow upwardly to the above ground collection area 250. This processis commonly referred to as artificial gas lift.

In another application for nitrogen rich gas in accordance with thepresent invention, the gas is used to stimulate the well in the downholeregion to enhance gas and/or recovery. More specifically, the walls ofthe wellbore in the downhole region characteristically have cracks orfissures through which the gas and/or oil emerges from the reservoir. Asthe pressure in the reservoir decreases, the fissures begin to closethereby lowering production. The most common form of stimulating thedownhole region is by acidizing or fracturing the wellbore. The nitrogenrich gas produced in accordance with the present invention can be usedas a carrier for the acid to treat the wellbore. The nitrogen rich gasexpands the volume of the acid, retards the reaction rate of the acidresulting in deeper penetration and permits faster cleanup because thereis less liquid to be displaced by the high energy nitrogen rich gas.

Cracking of the wellbore in the downhole region can be performed bypumping a fluid such as acid, oil, water or foam into a formation at arate that is faster than the existing pore structure will accept. Atsufficiently high pressures, the formation will fracture, increasing thepermeability of the downhole. When the stimulation procedure iscompleted, the pressure in the formation will dissipate and the fracturewill eventually close. Sand and/or glass beads or other so-called“poppants” may be injected into the formation and embedded in thefractures to keep the fractures open. The nitrogen rich gas produced inaccordance with the present invention may be used as a carrier gas tocarry the poppants to the wellbore.

It is well established that the pressure in a reservoir (formationpressure) provides for the flow of gas and/or oil to the downholeregion. As the reserves of gas and/or oil become depleted, the formationpressure decreases and the flow gradually decreases toward the well.Eventually the flow will decrease to a point where even well stimulationtechniques as previously described will be insufficient to maintain anacceptable productivity of the well. Despite the reduced formationpressure, nonetheless, the reservoir may still contain significantamounts of gas and/or oil reserves.

In addition, gas-condensate reservoirs contain gas reserves which tendto condense as a liquid when the formation pressure decreases belowacceptable levels. The condensed gas is very difficult to recover.

The lack of formation pressure in a reservoir can be remedied byinjecting a nitrogen rich gas directly into the reservoir. Referring toFIG. 9, a nitrogen rich gas production assembly of the type shown inFIGS. 1 and 2 is shown generally by numeral 252. The assembly isconstructed above a gas and/or oil reservoir 254. Nitrogen rich gas ispumped down the well, often called an injector well 200 a, through atubing 256 to exert pressure on the reserves in the direction of thearrow. The increased pressure on the gas and/or oil causes the same toflow to a producing formation and up a producing well 200 b through atubing 258 into an above ground collection vessel 260.

The production of a nitrogen rich gas in accordance with the presentinvention and its delivery to a well and/or a reservoir is less costlyand more reliable than conventional systems using cryogenic nitrogen andthe like, and safer than using air or any gas containing appreciableamounts of oxygen.

EXAMPLE 1

The flow rate of nitrogen rich gas to the drilling region of an oiland/or gas well or a geothermal well can vary over a wide rangedepending on the size of the downhole, the depth of the well, the rateof drilling, the size of the drilling pipe, and the makeup of thegeologic formation through which the well must be drilled.

A typical drilling operation will require the production of from 1,500to 3,000 standard cubic feet per minute (scfm) of nitrogen gas from anair separation system which can be anyone of a number of conventionalsystems including an air membrane separation system or a pressure swingadsorption system.

The purity of the nitrogen gas may vary, but is nominally set at no morethan about 5% to 8% by volume of oxygen. The resulting nitrogen rich gasis then pressurized up to a pressure of from about 1,500 to 2,000 psigbefore being passed to the drilling region.

An average drilling operation will take about five days to two weeks,although difficult geologic formations may require several months ofdrilling. The nitrogen rich gas delivery system is designed forcontinuous operation and all of the nitrogen rich gas is generatedon-site without the need for external nitrogen replenishment requiredfor cryogenically produced liquid nitrogen delivery systems.

EXAMPLE 2

In a typical underbalanced drilling operation, 500 to 800 scfm (standardcubic feet per minute) of a nitrogen rich gas produced in accordancewith the present invention is commingled with drilling mud to reduce thehydrostatic weight of the drilling fluid in the downhole region of awell. This reduces or prevents an overbalanced condition where drillingfluid enters the formation, or mud circulation is lost altogether.Carefully adjusting the weight of the drilling fluid will keep theformation underbalanced, resulting in a net inflow of gas and/or oilinto the well.

EXAMPLE 3

If a drill string becomes stuck due to high differential pressure causedby combined hydrostatic and well pressure conditions, a nitrogen richgas at 1500-3000 scfm at pressures of 1000-2000 psig is injected downthe drill string to force the fluid up the annulus to the surface. Thereduced weight and pressure will help free the stuck pipe. In this case,the nitrogen rich gas is used as a displacement gas.

EXAMPLE 4

A naturally producing reservoir loses pressure (depletes) over time witha resulting loss in recoverable oil and/or gas reserves. Injection ofnitrogen at 1500 scfm or greater at various locations or injection siteswill keep the reservoir pressurized to extend its production life. Ingas condensate reservoirs, the pressure is kept high enough to preventgas condensation or liquification, which is difficult to remove onceliquified.

The nitrogen rich gas can be introduced into the producing wells bymeans of special valves in the production casing positioned in thedownhole region of the well. The lifting action of the nitrogen rich gasis one form of artificial gas lift as shown best in FIG. 8.

What is claimed is:
 1. A method for producing an inert rich gas for usein removing cuttings from a drilling region of a well comprising:removing at least a substantial portion of oxygen contained within afeed stream of air to produce the inert rich gas and an oxygen enrichedwaste gas; and supplying the inert rich gas to equipment for directionto the drilling region of the well at a pressure and flow ratesufficient to remove cuttings from the drilling region.
 2. The method ofclaim 1 wherein the well is an oil well, gas well, or combinationthereof.
 3. The method of claim 2 wherein the equipment comprises asurface equipment installation.
 4. The method of claim 1 wherein thestep of supplying the inert rich gas comprises boosting the pressure ofthe inert rich gas to a level sufficient to remove the cuttings from thedrilling region of the well.
 5. The method of claim 4 wherein thepressure of the inert rich gas is boosted to at least 200 psig.
 6. Themethod of claim 4 wherein the pressure of the inert rich gas is boostedto at least 1000 psig.
 7. The method of claim 4 wherein the inert richgas is nitrogen rich gas.
 8. The method of claim 7 wherein the supplyingstep comprises compressing the inert rich gas.
 9. The method of claim 8wherein the compressing step comprises boosting the pressure of theinert rich gas to a level sufficient for use as the drilling fluid. 10.The method of claim 9 wherein the drilling fluid is used to removecuttings from a drilling region and the pressure is boosted to at least200 psig.
 11. The method of claim 9 wherein tie drilling fluid is usedto remove cuttings from a drilling region and the pressure is boosted toat least 1000 psi.
 12. The method of claim 1 wherein the inert rich gasis nitrogen rich gas.
 13. The method of claim 12 wherein the nitrogenrich gas contains at least 85 percent nitrogen.
 14. The method of claim12 wherein the nitrogen rich gas contains at least 95 percent nitrogen.15. The method of claim 12 wherein the removing step comprises passing afeed stream of air through a membrane which preferentially separatesnitrogen gas from other components of the air stream.
 16. A method forproducing an inert rich gas for use in lightening a drilling fluidcomprising; removing at least a substantial portion of oxygen containedwithin a food stream of air by passing the feed stream of air through amembrane which preferentially separates the inert rich gas from othercomponents of the feed stream to produce the inert rich gas and anoxygen enriched waste gas; and supplying the inert rich gas to anequipment for combination with a drilling fluid, wherein the inert richgas has a flow rate up to 2000 scfm.
 17. The method of claim 16 whereinthe inert rich gas is nitrogen rich gas.
 18. The method of claim 16wherein the equipment comprises a surface equipment installation. 19.The method of claim 16 wherein the step of supplying the inert rich gascomprises compressing the inert rich gas.
 20. A method for producing aninert rich gas for use as a drilling fluid comprising: providing a feedstream of air; separating at least a substantial portion of the inertrich gas by passing tho feed stream of air through a membrane whichpreferentially separates inert rich gas from other components of thefeed stream of air; and supplying the inert rich gas to an equipment foruse as a drilling fluid, wherein the inert gas has a purity level up to96%.
 21. The method of claim 20 wherein the inert rich gas is nitrogenrich gas.
 22. The method of claim 20 wherein the equipment comprises asurface equipment installation.
 23. A method for producing nitrogen richgas for use in reducing a density of a cement-like material used tosecure casings in a well comprising: removing at least a substantialportion of oxygen contained within a feed stream of air to produce thenitrogen rich gas and an oxygen enriched waste gas by passing the feedstream of air through a membrane which preferentially separates nitrogengas from other components of the feed stream, and supplying the nitrogenrich gas to an equipment fur combination with the cement-like material,wherein the nitrogen rich gas has a purity level up to 95%.
 24. Themethod of claim 23 wherein the wall is an oil or gas well.
 25. Themethod of claim 23 wherein the equipment comprises a surface equipmentinstallation.
 26. The method of claim 23 wherein the supplying stepcomprises compressing the nitrogen rich gas.
 27. A method for producinga nitrogen rich gas for use in enhancing gas or oil production byassisting gas or oil to rise out of a well comprising; removing at leasta substantial portion of oxygen contained within a feed stream of air toproduce a nitrogen rich gas and an oxygen enriched waste gas by passingthe feed stream of air through a membrane which preferentially separatesnitrogen gas from other components of the ford stream; and supplying thenitrogen rich gas to an equipment for use in assisting the gas or oil torise out of the well.
 28. The method of claim 27 wherein said nitrogenrich gas contains at least 85 percent nitrogen.
 29. The method of claim27 wherein said nitrogen rich gas contains at least 95 percent nitrogen.30. The method of claim 27 wherein the supplying step comprises boostingthe pressure of the nitrogen rich gas to a level sufficient to assistthe oil or gas to rise out of the well.
 31. The method of claim 30wherein the pressure of the nitrogen rich gas is boosted to at least 200psig.
 32. The method of claim 27 wherein the equipment comprises asurface equipment installation.
 33. A method of producing a nitrogenrich gas for use in carrying an additive into a well comprising:removing at least a substantial portion of oxygen contained within afeed stream of air to produce a nitrogen rich gas and an oxygen enrichedwaste gas by passing the feed stream of air through a membrane whichpreferentially separates nitrogen gas from other components of the feedstream; and supplying the inert rich gas to equipment for combinationwith the additive.
 34. The method of claim 33 wherein the additive isproppants.
 35. The method of claim 34 wherein the well contains cracksor tissues and wherein the proppants embed in the cracks or tissues. 36.The method of claim 34 wherein the proppants are selected from the groupconsisting of sand and glass beads.
 37. The method of claim 33 whereinthe additive is an acid.
 38. The method of claim 33 wherein thesupplying step comprises boosting the pressure of the nitrogen rich gasto a level sufficient to carry the additive into the wall.
 39. Themethod of claim 33 wherein the well is an oil or gas well.
 40. Themethod of claim 33 wherein the equipment comprises a surface equipmentinstallation.
 41. An apparatus for producing an inert rich gas for usein oil or gas drilling or completion operations comprising: a membraneseparator for separating at least a substantial portion of oxygencontained within a feed stream of air to produce an inert rich gas andan oxygen enriched waste gas; and a booster compressor to increase thepressure of the inert rich gas to a level sufficient for use in oil orgas drilling or completion operations and to supply the inert rich gasto equipment for use in oil or gas drillings or completion operations.42. The apparatus of claim 41 wherein aid inert gas is nitrogen richgas.
 43. The apparatus of claim 41 wherein said membrane separatorcomprises a plurality of bundles of hollow fiber semi-permeablemembranes and a central core tube.
 44. The apparatus of claim 41 furthercomprising a compressor for supplying the feed stream of air to themembrane separator.
 45. The apparatus of claim 41 further comprising aconduit for supplying the pressurized inert rich gas from the boostercompressor to equipment for use in oil or gas drilling or competitionoperations.
 46. The apparatus of claim 41 wherein the equipmentcomprises a surface equipment installation.
 47. A method for producingan inert rich gas for use in removing cuttings from a drilling region ofa wall comprising: removing at least a substantial portion of oxygencontained within a feed stream of air to produce an inert rich gas andan oxygen enriched waste gas; and supplying the inert rich gas toequipment for direction to the drilling region of the well to removecuttings from the drilling region.